Ladder station support assembly

ABSTRACT

A ladder station supporting device is provided which includes an upper holder assembly having an upper mounting body and a first vertically-oriented holder rotatably fastened to the upper mounting body; a lower holder assembly having a lower mounting body and a second vertically-oriented holder rotatably fastened to the lower mounting body; and a vertically-oriented articulation rod interconnecting the upper and lower holder assemblies, wherein the upper holder assembly may be adjustably positioned along an axis defined by the articulation rod.

CROSS-REFERENCE TO RELATED APPLICATIONS

(Not Applicable)

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

(Not Applicable)

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is related to window blind manufacturingequipment. In particular, the present invention relates to a ladderstation support assembly that is a subcomponent of a modular assemblystation which is utilized for assembling (i.e., stacking) a plurality ofslats for window blind units.

2. Background of the Invention

The automation of window blind construction has been advanced throughthe development of modular assembly stations for cutting and assemblinga plurality of slats for window blind units. One aspect of manufacturingblinds is the process of inserting each slat into a plurality ofladder-string openings. When the slats are stacked, at least twosymmetrically placed ladder-strings provide support for the slats as theslats are cradled between the rungs of the ladder-strings. To accomplishthis task, the modular assembly stations utilize a ladder-stringapplicator which typically includes a U-shaped space presenter housinghaving a plurality of pairs of opposing slat holders or spring clipledges which are utilized to support the slats once the slats have beeninserted into the ladder-string spaces and stacked.

This blind manufacturing process is best illustrated in U.S. Pat. No.6,003,218 to Schumann et al., entitled “Apparatus For Cutting andAssembling Slats For Window Blind Units”, subject matter of which isincorporated herein by reference. Schumann et al. teaches a modularassembly station for slotting and stringedly assembling a plurality ofwindow blind units. The assembly station includes a ladder-stringapplicator in a lateral spaced relationship and in alignment to aU-shaped space presenter housing having an entrance chamber forreceiving a slat. A conveyor is provided for receiving a slat andlaterally advancing it into the entrance chamber and ladder-stringapplicator. The conveyor includes a pusher that advances the slatthrough an elongated channel positioned in alignment with the entrancechamber of the U-shaped space presenter housing of the ladder-stringapplicator. Thereafter, the slat within the channel is longitudinallyadvanced by the pusher into the entrance chamber. Concurrently, one ormore ladder spaces of respectively one or more ladder-strings arepresented in the entrance chamber and the slat is positioned within theladder spaces. Once inserted within the space of the ladder-string, theslat is lifted by raising the elongate channel until the slat passesthrough opposing holders or spring clip ledges disposed at the top ofthe U-shaped space presenter housing of the ladder-string applicator.Once passed through the slot holders, the elongated channel islongitudinally extracted from the U-shaped space presenter housingleaving the slot resting on the top of the holders. The elongatedchannel is then lowered to its original position to await to bereinserted into the entrance chamber again and to await entry of thenext slat.

Another existing design for a ladder station support assembly is aU-shaped ladder station support assembly which features a pair ofopposing left and right slat holders (see FIGS. 1–6). The pair ofopposing left and right slat holders allow the stacking process to beperformed by two elongated channels, instead of just one elongatedchannel as taught in U.S. Pat. No. 6,003,218 to Schumann et al., subjectmatter of which is incorporated herein by reference. By utilizing twoelongated channels, the stacking process may be accomplished orcompleted twice as fast as compared to using a ladder station supportassembly that provides only a pair of opposing left and right slatholders.

A disadvantage to both the U-shaped space presenter housing of theladder-string applicators taught in U.S. Pat. No. 6,003,218 to Schumannet al. and the known U-shaped ladder support station (see FIGS. 1–6) isthat they require routine maintenance. In particular, springs areutilized in conjunction with the opposing slat holders or spring clipledges to bias the holders or clip ledges outward. Repetitive stackingcycles wear the springs out and the biased force becomes inconsistent ascompared to desired specifications. Thus, the aforementioned devicesmust be periodically refurbished with new springs and other internalparts such as bushings. Each time one of the aforementioned devices hasto be refurbished or replaced, the production line has to be stopped,which inhibits productivity. Moreover, the continuous refurbishment ofthe space presenter adds more expense to the manufacturing process. Fora more comprehensive understanding, the prior art U-shaped ladderstation support assembly will be discussed in greater detail in theDetailed Description section.

It would be desirable to provide a ladder station support assembly whichis more reliable than the aforementioned U-shaped space presenterhousings of the ladder-string applicator taught in U.S. Pat. No.6,003,218 to Schumann et al. and the known U-shaped ladder supportstation (see FIGS. 1–6). An ideal ladder station support assembly wouldbe inexpensive, have less parts, and require less maintenance. Moreover,it would be desirable to provide a ladder station support assembly whichwould be more durable and which can withstand more stacking cyclesbetween routine maintenance. Furthermore, an ideal ladder stationsupport assembly would be able to be integrated or retrofit into anexisting assembly workstation or incorporated into new designs.Additionally, it would be advantageous to provide a level ofarticulation and adjustability to the ladder station support assemblythat would allow the height of the opposing slat holder be adjusted toaccommodate varying production run parameters.

SUMMARY OF THE INVENTION

According to an embodiment of the present invention, a ladder stationsupporting device is provided which includes an upper holder assemblyhaving an upper mounting body and a first vertically-oriented holderrotatably fastened to the upper mounting body; a lower holder assemblyincluding a lower mounting body and a second vertically-oriented holderrotatably fastened to the lower mounting body; and a vertically-orientedarticulation rod interconnecting the upper and lower holder assemblies,wherein the upper holder assembly may be adjustably positioned along anaxis defined by the articulation rod.

According to an aspect of the present invention, the upper and lowermounting body each have a vertically-oriented recess adapted to receivethe respective first and second holder. The recess has a holderinterface surface and a perimeter wall having a lower perimeter portion,an upper perimeter portion, and a side perimeter portion. According toanother aspect of the present invention, the first and second holdereach have a general rhomboid shape. In another aspect of the presentinvention, the first and second holder each have a stack supportingside, a resting side opposing the stack supporting side, a sliding edgeside, and a stopping edge side opposing the sliding edge side.

According to other aspects of the present invention, the resting side isadapted to rest on the lower perimeter portion of the recess when thefirst or second holder is in a non-engaged state. Additionally, theresting side contacts the lower perimeter portion of the recess when thefirst or second holder supports a stack of slats. And yet another aspectof the present invention includes the first and second holder each beingadapted to recede into the recess when a force is exerted on the slidingedge of the first or second holder. Furthermore, when the first orsecond holder is fully receded into the recess, the stopping edge of thefirst or second holder contacts the side perimeter portion of therecess.

Additionally, another embodiment of the present invention includes aladder station support device which includes an upper holder assemblyconsisting of an upper mounting body, a first vertically-orientedholder, a first bolt for rotatably fastening the first holder to theupper body, and a first set screw; a lower holder assembly consisting ofa lower mounting body, a second vertically-oriented holder, a secondbolt for rotatably fastening the second holder to the lower body, and asecond set screw; and an articulation rod interconnecting the upper andlower holder assemblies, wherein the upper holder assembly may beadjustably positioned along an axis defined by the articulation rod andsecured thereto by the first set screw, and the lower holder assemblymay be secured to a distal end of the articulation rod by the second setscrew.

Another embodiment is provided which is an assembly machine for stackingblind slats in combination with a plurality of ladder station supportdevices installed onto a portion of the assembly machine. Each pluralityof ladder station support devices includes a left and right supporthalf. The left support half includes a left upper holder assemblyincluding a left upper mounting body and a vertically-oriented firstleft holder rotatably fastened to the left upper mounting body; a leftlower holder assembly including a left lower mounting body and avertically-oriented second left holder rotatably fastened to the leftlower mounting body; and a vertically-oriented left articulation rodinterconnecting the left upper and lower holder assemblies, wherein theleft upper holder assembly may be adjustably positioned along a firstaxis defined by the left articulation rod. The right support halfincludes a right upper holder assembly including a right upper mountingbody and a vertically-oriented first right holder rotatably fastened tothe right upper mounting body; a right lower holder assembly including aright lower mounting body and a vertically-oriented second right holderrotatably fastened to the right lower mounting body; and avertically-oriented right articulation rod interconnecting the rightupper and lower holder assemblies, wherein the right upper holderassembly may be adjustably positioned along a second axis defined by theright articulation rod. Furthermore, the left and right support halvesare vertically aligned and laterally aligned with each other such that aleft upper supporting side and left upper distal tip of the left upperholder is proximate to and aligned with a right upper supporting sideand right upper distal tip of the right upper holder, and such that aleft lower supporting side and left lower distal tip of the left lowerholder is proximate to and aligned with a right lower supporting sideand right lower distal tip of the right lower holder.

There are many advantages that the present invention has over existingprior art solutions. Overall, the present invention overcomes theaforementioned disadvantages by providing a ladder station supportassembly which is simple and reliable. For instance, the presentinvention uses significantly less parts than the prior art. Inparticular, the present invention utilizes no springs or other internalmoving parts. Therefore, the previously existing problem with respect toworn out springs and unevenly distributed biased springs is eliminated.The only parts that move in the production mode are the slat holders.This simple design results in a ladder station support which may becycled more, and yet, requires less maintenance. Moreover, the presentinvention may be manufactured for significantly less (about fiftypercent) than the previously described U-shaped ladder station support.

Furthermore, the ladder station support assembly is designed such thatit may be retrofitted into an existing assembly station without anymodification to the existing assembly station. Thus, the ladder stationsupport assembly is considered a line replaceable unit which may bereadily stored as a spare and easily installed into an assembly stationwhen an existing ladder station support assembly (such as the prior artpreviously described) or the instant ladder station support assemblyrequires maintenance or replacement.

Other exemplary embodiments and advantages of the present invention maybe ascertained by reviewing the present disclosure and the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is further described in the detailed descriptionthat follows, by reference to the noted drawings by way of non-limitingexamples of preferred embodiments of the present invention, in whichlike reference numerals represent similar parts throughout several viewsof the drawings, and in which:

FIG. 1 shows a prior art U-shaped ladder station support assembly;

FIG. 2 shows a plurality of prior art U-shaped ladder station supportassemblies (three places) configured such that they may be integratedinto a modular assembly station;

FIG. 3 is front perspective of a prior art U-shaped ladder stationsupport assembly having three slats already inserted into ladder-stringspaces and stacked, and another slat being lifted into the stack by anelongated channel;

FIG. 4 is front perspective of the upper opposing left and right slatholders of the prior art U-shaped ladder station support assembly, whichhave three slats already inserted into ladder-string spaces and stacked,and another slat being lifted into the stack by an elongated channel;

FIG. 5 is the same view as FIG. 4, except the elongated channel with aslat is being lifted through the upper opposing left and right slatholders;

FIG. 6 is the same view as FIGS. 4 and 5, except the slat has beenlifted through the upper opposing left and right slat holders, theelongated channel has been extracted, and the slat is now resting on theupper opposing left and right slat holders;

FIG. 7 shows an exemplary embodiment of a ladder station supportassembly according to an aspect of the present invention;

FIG. 8 shows a plurality of the ladder station support assemblies (threeplaces) configured such that they may be integrated into a modularassembly station, according to an aspect of the present invention;

FIG. 9 is front perspective of the exemplary embodiment of a ladderstation support assembly having three slats already inserted intoladder-string spaces and stacked, and another slat being lifted into thestack by an elongated channel, according to an aspect of the presentinvention;

FIG. 10 is front perspective of the upper opposing left and right slatholders of the exemplary embodiment of the ladder station supportassembly, which has three slats already inserted into ladder-stringspaces and stacked, and another slat being lifted into the stack by anelongated channel, according to an aspect of the present invention;

FIG. 11 is the same view as FIG. 10, except the elongated channel with aslat is being lifted through the upper opposing left and right slatholders, according to an aspect of the present invention; and

FIG. 12 is the same view as FIGS. 10 and 11, except the slat has beenlifted through the upper opposing left and right slat holders, theelongated channel has been lowered, and the slat is resting on the upperopposing left and right slat holders, according to an aspect of thepresent invention

DETAILED DESCRIPTION OF THE PRESENT INVENTION

The particulars shown herein are by way of example and for purposes ofillustrative discussion of the embodiments of the present invention onlyand are presented in the cause of providing what is believed to be themost useful and readily understood description of the principles andconceptual aspects of the present invention. In this regard, no attemptis made to show structural details of the present invention in moredetail than is necessary for the fundamental understanding of thepresent invention, the description taken with the drawings makingapparent to those skilled in the art how the several forms of thepresent invention may be embodied in practice.

The Detailed Description will first provide a description of the priorart U-shaped ladder station support which is currently utilized inmodular assembly stations. FIGS. 1 through 6 are provided to assist inthe description of the prior art U-shaped ladder station support. Next,a detailed description of an exemplary embodiment of the presentinvention and various aspects thereof, will then be provided. FIGS. 7through 12 are presented to assist in the description of the presentinvention.

DETAILED DESCRIPTION OF PRIOR ART

FIG. 1 is a perspective view of the prior art U-shaped ladder supportassembly 2. The ladder support assembly 2 has a rigid U-shaped frame 7comprising a left vertical frame portion 27, a right vertical frameportion 28, and lower cross member portion 29. The ladder supportassembly 2 may be attached to the modular assembly station with mountinghardware 26, such as bolts. The ladder support assembly 2 has two pairof opposing left and right slat holders 10, 12, 14, 16. Each slat holderis part of an assembly further comprising a cover plate 11, 13, 15, 17,a spring 18, a pin 20, bushings 22, and bolts 24.

FIG. 2 shows a plurality of prior art U-shaped ladder station supportassemblies 2 (three places) configured as they would be integrated intoa modular assembly station (not shown) which is utilized for assemblinga plurality of slats for window blind units. The ladder stationassemblies 2 are positioned laterally next to each other and are inalignment with one another such that the slats may be lifted through theopposing left and right slat holders and stacked by an elongated channel(not shown).

FIG. 3 is front perspective of a prior art U-shaped ladder stationsupport assembly 2 having three slats already inserted intoladder-string spaces 5 (of ladder-string 4) and stacked, and anotherslat 8 being lifted into the stack 6 by an elongated channel 144. FIG. 4is front perspective of the upper opposing left and right slat holders10, 14 of the prior arc U-shaped ladder station support assembly 2,which has three slats already inserted into ladder-string spaces 5 andstacked, and another slat 8 being lifted into the stack 6 by anelongated channel 144. FIG. 5 is the same view as FIG. 4, except theelongated channel 144 with a slat 8 is being lifted through the upperopposing left and right slat holders 10, 14. FIG. 6 is the same as FIGS.4 and 5, except the slat 8 has been lifted through the upper opposingleft and right slat holders 10, 14, the elongated channel 144 has beenextracted, and the slat 8 is resting on the upper opposing left andright slat holders 10, 14 and is now part of the stack 6.

General Description of Exemplary Embodiment of Ladder Station SupportAssembly

The present invention is now described herein below. FIG. 7 shows anexemplary embodiment of the present invention which is a ladder stationsupport assembly 1 including a left support half 40 and a right supporthalf 42. Each support half 40, 42 includes at least three maincomponents, including an articulation rod 44, an upper holder assembly46, and a lower holder assembly 48.

The articulation rod 44 is preferably made from a high strength alloy,for instance, stainless steel. The length and diameter of thearticulation rod 44 may vary according to the dimensions and size of theassembly station or stacking machine of which the support half 40, 42 isto be installed.

Both upper 46 and lower 48 holder assemblies have at least two maincomponents, including a mounting body 50 and a slat holder 52. Themounting body 50 may be constructed of a variety of materials, such asmetal (for example steel or aluminum), plastic, and resin material toname just a few exemplary materials. This material list is merelyexemplary and is not intended to be limiting.

The slat holders 52 may be made from a variety of materials, such asplastic (i.e. polyethylene, polypropylene, TEFLON® (i.e., PTFE)) ormetal (i.e. aluminum) to name just a few examples. This material list ismerely exemplary and is not intended to be limiting. Preferably, thematerial utilized for manufacturing the slat holders 52 will exhibitsufficient rigidity and durability to withstand thousands of slatlifting cycles. However, preferably, the slat holder 52 is made from amaterial which reduces friction when the elongated channel 144 (seeFIGS. 9–12) is brought into contact with the opposing slat holders 52.

Detailed Description of Left and Right Upper Mounting Bodies

The structure of the left 54 and right 56 upper holder assembly mountingbody 50, as illustrated in FIGS. 7 through 12, is now herein describedbelow. It is noted that the left upper mounting body 54 is a mirrorimage of the right upper mounting body 56. Therefore, for purposes ofthis description, the left and right upper holder assembly mountingbodies 54, 56 are generally referred to as upper mounting bodies 54, 56.The exemplary upper mounting body 54, 56 has a generally rectangularshape, however, the shape of the upper mounting body 54, 56 may conformto any other shapes which accomplish the same function. For descriptivepurposes, the upper mounting bodies 54, 56 have a first holder adaptingside 58, a first back side 60, a first upper side 62, a first lower side64, a first holder deployment side 66, and a first set screw receivingside 68 which opposes the first holder deployment side 66. The mountingbody 54, 56 may also have a first chamfered edge 70 at about 45 degreeswhere the first holder deployment side 66 and first lower side 64 meet.

The upper mounting body 54, 56 is provided with a first articulationbore 72 for receiving the articulation rod 44. The first articulationbore 72 is positioned lateral and parallel to the first holderdeployment side 66. Thus, the first articulation bore 72 has a firstupper bore opening on the first upper side 62, and a first lower boreopening 76 (not shown) on the first lower side 64. In the exemplaryembodiment, the second bore 76 opening is substantially positioned onthe first chamfered edge 70 as best illustrated in FIG. 9. The diameterof the first articulation bore 72 is slightly larger than the diameterof the articulation rod 44. Therefore, a sliding fit interface havingrelatively close tolerances is formed between the surface of the firstarticulation bore 72 and the outer surface of the articulation rod 44.This fastening interface provides axial (i.e. along the axial orlongitudinal length of the rod 44) and radial (rotatably around thesurface of the rod 44) adjustability between the upper holder assembly46 and the articulation rod 44 as shown by the motion arrows in FIG. 7.A recessed set screw 78, such as an Allen head screw, is utilized tosecure the articulation rod 44 within the upper mounting body 54, 56. Inparticular, a first set screw hole 80 having receiving threads isprovided within the upper mounting body 54, 56. A first set screw hole80 is oriented normal to and intersects the first articulation bore 72.Therefore, the set screw 78 may be tightened directly to surface of thearticulation rod 44.

The upper mounting body 54, 56 has a first recess 82 formed or milledwithin the upper mounting body 54, 56 which is adapted to receive theslat holder 52. The first recess 82 is formed in the first holderadapting side 58 and the first holder deployment side 66 of the uppermounting body 54, 56, which results in a first perimeter wall 84 and afirst holder interface surface 86 formed in the upper mounting body 54,56. The first perimeter wall 84 has a first lower perimeter portion 88,a first upper perimeter portion 90, and a first side perimeter portion92. The depth of the first recess is preferably sufficient tosubstantially accept the thickness of the slat holder 52. The length andwidth of the first recess 82 should be sufficient enough to allow theslat holder 52 to rotate a desired or specific range of upward anddownward motion. The shape of the exemplary embodiment of the recess 82(see FIGS. 7–12) is generally rectangular. However, the first recess 82may have a variety of shape as long as it performs the same function.This aspect of the present invention will be described in greater detaillater within the specification.

A first slat holder mounting hole 94 is provided in the upper body 54,56 for mounting the slat holder 52. In particular, the first holdermounting hole 94 is positioned in a region of the lower corner of thefirst recess 82. The first holder mounting hole 94 is oriented normal toand offset from the articulation bore 72 and has receiving threads toaccept a bolt 96 for fastening the slat holder 52. Preferably, the bolt96 will have machine threads and have a head adapted to receive or Allenhead wrench and also have knurled edges. The attachment of the slatholder 52 within the first recess 82 and the interaction of the slatholder 52 with respect to the first perimeter wall 84 and the firstholder interface surface 86 will be described in further detail later inthe specification.

Detailed Description of Left and Right Lower Mounting Bodies

The structure of the left and right lower holder assembly 48 mountingbodies 98, 100 are now herein described below. The left and right lowerholder assembly mounting bodies 98. 100 are generally referred to as thelower mounting bodies 98, 100. For descriptive purposes, the lower body98, 100 has a second holder adapting side 106, a second back side 108, asecond upper side 110, a second lower side 112, a second holderdeployment side 114, and a second set screw receiving side 117 whichopposes the second holder deployment side 114. Moreover, the shape ofthe lower mounting body 98, 100 may conform to other shapes and formsthat will perform the same function.

The exemplary lower mounting bodies 98, 100 shown in FIGS. 7 through 12have a similar structural features to that of the upper mounting body54, 56, however, the length L_(L) of the left lower mounting body 98(see FIG. 9) and length L_(R) of the right lower mounting body 100 (seeFIG. 9) may not the same with respect to each other in the exemplaryembodiment. Furthermore, the chamfered edges 102, 104 on the lower body98, 100 have different angles of inclination (β, θ) as compared to theupper body 54, 56 which are about 45 degrees. In particular, the leftlower mounting body 98 may have a left lower mounting body chamferededge 102 with an angle of inclination representative of β where thesecond holder deployment side 114 and second lower side meet 112. Theleft lower chamfered edge 102 may generally reach beyond about half-wayupwards on the second holder deployment side 114. In a similar manner,the right lower mounting body 100 may have a right lower mounting bodychamfered edge 104 with an angle of inclination representative of θwhere the second holder deployment side 114 and second lower side meet112. The right lower chamfered edge 104 may reach to generally about atthe second lower perimeter wall portion 128 begins. The aforementionedstructural features are provided such that mounting bodies 98, 100 maybe adapted to and fastened to mounting structure of the modular assemblystation (not shown). However, it is noted that mounting bodies 98, 100may conform to various shapes and sizes which perform the same function,and therefore, should not be limited to the exemplary shapes hereindescribed.

The lower mounting body 98, 100 has a second articulation bore 116 (seeFIG. 9) for receiving the articulation rod 44. The second articulationbore 116 is positioned lateral and parallel to the second holderdeployment side 114. The second articulation bore 116 has a second upperbore opening 118 on the second upper side 110. In the exemplaryembodiment shown in FIGS. 7 through 12, the second articulation bore 116dead heads generally at about half the length of the second holderdeployment side 114 (see FIG. 9). Thus, the exemplary embodiment doesnot incorporate a second lower bore opening, however, an alternativeembodiment may utilize a second lower bore opening (not shown). Thediameter of the second articulation bore 116 is slightly larger than thediameter of the articulation rod 44. Therefore, a sliding fit interfaceis formed between the surface of the second articulation bore 116 andthe outer surface of the articulation rod 44. This fastening interfaceprovides radial (rotatably around the surface of the rod) adjustabilityabout the articulation rod 44. A recessed set screw 78, such as an Allenhead screw, is utilized to secure the rod 44 within the lower mountingbody 98, 100. In particular, a second set screw hole 120 havingreceiving threads is provided in the lower mounting body 98, 100 and isoriented normal to and intersects the second articulation bore 116.Therefore, the set screw 78 may be tightened directly to surface of thearticulation rod 44.

The lower mounting body 98, 100 has a second recess 122 formed or milledwithin the lower mounting body 98, 100 which is adapted to receive theslat holder 52. The exemplary embodiment of the second recess shown inFIGS. 7 through 12 has a generally rectangular shape. The second recess122 is formed in the second holder adapting side 106 and the secondholder deployment side 114 of the lower mounting body 98, 100, whichresults in a second perimeter wall 124 and a second holder interfacesurface 126 formed in the lower mounting body 98, 100. The secondperimeter wall 124 has a second lower perimeter portion 128, a secondupper perimeter portion 130, and a second side perimeter portion 132.The depth of the second recess is preferably sufficient to substantiallyaccept the thickness of the slat holder 52. The length and width of thesecond recess 122 should be sufficient enough to allow the slat holder52 to have desired or specific range of upward and downward motion. Thisaspect of the present invention will be further discussed later in thespecification.

A second holder mounting hole (not shown) is provided in the lower body98, 100 for mounting the slat holder 52. In particular, the secondholder mounting hole is positioned in a region of the lower corner ofthe second recess 122. The second holder mounting hole is orientednormal to and offset from the second articulation bore 116 and hasreceiving threads to accept a bolt 78 for fastening the holder.Preferably, the bolt 78 will have machine or fine threads, and have ahead adapted to receive an Allen head wrench, and also have knurlededges. The attachment of the slat holder 52 within the second recess 122and the interaction of the slat holder 52 with respect to the secondperimeter wall 124 and the second holder interface surface 126 will bedescribed in further detail later in the specification.

The lower mounting body 98, 100 further includes a plurality of mountingbores 134 adapted to rigidly fasten each support half 40, 42 to themodular assembly station or stacking machine. In the exemplaryembodiment, a pair of mounting bores 134 are provided in the secondlower surface 112. Other various bolt patterns may also be utilized inother embodiments. Moreover, each support half 40, 42 may be fastened toan assembly station or stacking device in other manners of which one ofordinary skill in the art would implement.

Holder Description and Dynamics of Holder within Mounting Body Recess

The following section now describes various aspects of slat holder 52.This description applies to both the upper and lower holder assemblies46, 48, and thus, a general description is provided which is applicableto each mounting body 50 and slat holder 52. Each slat holder 52 hasfour sides and has a generally parallelogram shape, in particular, arhomboid shape. However, the rhomboid-shaped slat holder 52 may not be aperfect parallelogram or rhomboid. For descriptive purposes, the slatholder 52 has a lifting side 136 (see FIGS. 10–12), a resting side 138which opposes the lifting side 136, a sliding edge side 140 and astopping edge side 142 which opposes the sliding edge side 140. For theshown exemplary embodiment of the slat holder 52, the lifting side 136is slightly longer than the resting side 138. The lifting side 136 isused as a rest for the stack of blinds 6 as shown in FIGS. 9 through 12.The sliding edge side 140, is preferably smooth, and is the side ofwhich the elongated channel 144 is contacts while lifting the slat 8 upinto the slat stack 6. The resting side 138 of the slat holder 52contacts the lower perimeter side 88, 128 when the slat holder 52 is ina resting position as shown in FIGS. 10 and 12. The stopping edge side142 contacts the side perimeter wall 92, 132 when the slat holder 52 ispushed upward inside the recess 82, 122 by the elongated channel 144when it is lifted through the opposing left and right slat holders 52 asshown in FIG. 11.

The slat holder 52 is rotatably attached by the bolt 78 such that theslat holder 52 may freely move from its resting position (see FIGS. 9,10, 12) to the pushed up position (see FIG. 11). It is noteworthy tomention that the present invention utilizes no springs orresilient-biased elements to assist in actuating the slat holder 52which reduces the number of parts of which are subject to wear and tear.Thus, the slat holder 52 in the present invention is designed such thatit may be easily pushed upward with minimal resistance by the elongatedchannel 144 that is lifting the slat 8. Furthermore, the slat bolder 52falls back to the resting position (see FIGS. 9, 10, 12) withoututilizing a spring such as in the prior art device. The feature isaccomplished by providing a slat holder 52 which has a center of gravityoffset from the axis of which it rotates about, the axis of which isdefined by the centerpoints of holder mounting hole 94 and bolt 96. As aresult, once the elongated channel 144 with the slat 8 passes throughthe pair of opposing slat holders 52, the slat holders 52 swing downwarduntil the resting side 142 of the slat holder 52 contacts the lowerperimeter wall 88, 128 (see FIGS. 9, 10, 12).

Integration of Ladder Station Support Assemblies into Assembly Station

As shown in FIG. 8, a plurality of ladder station support assemblies 1are typically utilized together when assembling window blind units. Inparticular, the plurality of vertically-oriented ladder station supportassemblies 1 are positioned in line with each other such that a row aleft support halves 40 are in alignment and such that a row of rightsupport halves 42 are in alignment. The upper holder assemblies 46(i.e., both left and right) should be adjusted to the same height oneach respective articulation rod 44.

It is noteworthy to mention that present invention may be adapted orintegrated into a variety of assembly stations or stacking machines, andis not limited to only usage in assembly machines utilized formanufacturing blinds. Thus, the scope of the present invention shouldnot be limited to blind stacking machines.

Although the invention has been described with reference to severalexemplary embodiments, it is understood that the words that have beenused are words of description and illustration, rather than words oflimitation. Changes may be made within the purview of the appendedclaims, as presently stated and as amended, without departing from thescope and spirit of the invention in its aspects. Although the inventionhas been described with reference to particular means, materials andembodiments, the invention is not intended to be limited to theparticulars disclosed; rather, the invention extends to all functionallyequivalent structures, methods, and uses such are within the scope ofthe appended claims.

1. A ladder station support device comprising: an upper holder assemblycomprising an upper mounting body and a first holder rotatably fastenedto said upper mounting body; a lower holder assembly comprising a lowermounting body and a second holder rotatably fastened to said lowermounting body; a vertically-oriented articulation rod interconnectingsaid upper and lower holder assemblies, wherein the upper holderassembly may be adjustably positioned along an axis defined by saidarticulation rod; and wherein said first and second holder each having ageneral rhomboid shape.
 2. The device according to claim 1, said upperand lower mounting body each having a vertically-oriented recess adaptedto receive said respective first and second holder, said recess having aholder interface surface and a perimeter wall having a lower perimeterportion, an upper perimeter portion, and a side perimeter portion. 3.The device according to claim 1, said first and second holder eachhaving a stack supporting side, a resting side opposing said stacksupporting side, a sliding edge side, and a stopping edge side opposingsaid sliding edge side.
 4. The device according to claim 3, wherein saidresting side is adapted to contact and rest on said lower perimeterportion of the recess when said first or second holder is in anon-engaged state.
 5. The device according to claim 3, wherein saidresting side contacts said lower perimeter portion of said recess whensaid first or second holder supports a stack of slats.
 6. The deviceaccording to claim 3, wherein said first and second holder are eachadapted to recede into the recess when a force is exerted on saidsliding edge of said first or second holder.
 7. The device according toclaim 6, wherein when said first or second holder is fully receded intothe recess, said stopping edge of said first or second holder contactssaid side perimeter portion of the recess.
 8. A ladder station supportdevice comprising: an upper holder assembly consisting of an uppermourning body, a first holder, a first bolt for rotatably fastening saidfirst holder to said upper body, and a first set screw; a lower holderassembly consisting of a lower mounting body, a second holder, a secondbolt for rotatably fastening said second holder to said lower body, anda second set screw; and a vertically-oriented articulation rodinterconnecting said upper &id lower holder assemblies, wherein saidupper holder assembly may be adjustably positioned along an axis definedby said articulation rod and secured thereto by said first set screw,and said lower holder assembly may be secured to a distal end of saidarticulation rod by said second set screw.
 9. The device according toclaim 8, said upper and lower mounting body each having avertically-oriented recess adapted to receive said respective first andsecond holder, the recess having a holder interface surface and aperimeter wall having a lower perimeter portion, an upper perimeterportion, and a side perimeter portion.
 10. The device according to claim9, said first and second holder each having a stack supporting side, aresting side opposing said stack supporting side, a sliding edge side,and a stopping edge side opposing said sliding edge side.
 11. The deviceaccording to claim 10, wherein said resting side is adapted to rest onsaid lower perimeter portion of the recess when said first or secondholder is in a non-engaged state.
 12. The device according to claim 11,wherein said resting side contacts said lower perimeter portion of therecess when said first or second holder supports a stack of slats. 13.The device according to claim 11, wherein said first and second holderare each adapted to recede into the recess when a force is exerted onsaid sliding edge of said first or second holder.
 14. The deviceaccording to claim 13, wherein when said first or second holder is fullyreceded into the recess, said stopping edge of said first or secondholder contacts said side perimeter portion of the recess.
 15. Thedevice according to claim 8, said first and second holder each having ageneral rhomboid shape.
 16. A ladder station support device comprising:an upper holder assembly comprising an upper mounting body and a firstholder rotatably fastened to said upper mounting body; a lower holderassembly comprising a lower mounting body and a second holder rotatablyfastened to said lower mounting body; a vertically-oriented articulationrod interconnecting said upper and lower holder assemblies, wherein theupper holder assembly may be adjustably positioned along an axis definedby said articulation rod; wherein said upper and lower mounting bodyeach having a vertically-oriented recess adapted to receive saidrespective first and second holder; and wherein said recess having aholder interface surface and a perimeter wall having a lower perimeterportion, an upper perimeter portion, and a side perimeter portion.